Apparatus and method for removing pressure adhesive labels from backing and affixing to target substrate

ABSTRACT

A system, apparatus, and method for removing pressure adhesive indicia, such as labels or stamps, from their backing and affixing the same to a target substrate is provided. The automated process affixes stamps, for example, to the target substrate with both speed and precision of placement. Desired stamps can be selectively removed from a backing, for example, can be placed on variable locations upon the target substrate, and can be affixed in the desired orientation with precise spacing between stamps. The precision of affixation afforded by this system is commensurate with philatelic standards and is suitable for all pressure adhesive indicia where rapid and precise placement is desired for aesthetic or other reasons.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation and claims the prioritybenefit of U.S. patent application Ser. No. 11/701,402 filed Feb. 2,2007, now U.S. Pat. No. 8,408,271 issued Apr. 2, 2013, the disclosure ofwhich is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to system, apparatus, and methodfor removing pressure adhesive indicia from their backing and affixingthe same to a target substrate.

BACKGROUND OF THE INVENTION

Currently, there is a need to remove fee indicia, such as stamps, from asheet, or pane, by hand and affix the same to a target substrate, suchas an envelope, by hand. Both the speed of this operation and theaccuracy of the stamp affixation placement is limited by human capacity.In some circumstances, the need for precision placement contributesdramatically to the labor time required to affix the stamps to thetarget substrate.

For example, precise placement of the stamp on the target substrate isdesired on philatelic items. Philately, that is stamp collecting, is anextremely popular hobby, recognized by many as the most popular hobby inthe world. National postal administrations, as well as private sectorcompanies, create items bearing significant postmarks specifically toappeal to those who participate in stamp collecting. In order to beregarded as collectible quality, the stamps must be affixed precisely ina specific placement on the target substrate.

To meet philatelic standards, stamps are, on the average, manuallyremoved and affixed to the target substrate with precision placement ata rate of 150 stamps per man-hour. In fact, the precision placementcontributes significantly to the time requirements. Stamps must beplaced in a consistent location on the target substrate, in a specificorientation and, when more than one stamp is to be affixed, they must begrouped in a specific configuration and spaced precisely from oneanother. The placement surface of the target substrate necessarilyvaries as well, such as a small envelope, a large document envelope, ora package. This variability contributes to the demands of manual-stampplacement.

In addition to the arena of stamp collecting, other applications existin which removal of pressure adhesive indicia, delivery labels forexample, from sheets or sheets and subsequent precise placement isdesirable. An increase in production rate of this process would benefitany high volume delivery service. Precise placement can contribute tothe ease and speed of future target substrate processing, such ascancelling of delivery fee indicia and verifying delivery fee amount.Precise placement of labels has aesthetic appeal and can contribute toproduct marketability and sales.

The application for automated removal, affixation, and canceling ofself-adhesive indicia is broader than delivery of goods. Other examplesinclude cigarette packages which are labeled, and then the affixed labelis cancelled for tax purposes. Presently, this labeling and cancellingstamp by tax stamp is performed by hand. The invention provided hereincould readily be utilized by for such practices improving speed andefficiency of the process.

Accordingly, a need exists to reduce the labor requirements whileincreasing the speed and accuracy of removing pressure adhesive indicia,such as labels, from backing sheets and precisely affixing the same to atarget substrate.

SUMMARY OF THE CLAIMED INVENTION

Any reference to self-adhesive indicia, pressure adhesive indicia,labels, and stamps is merely exemplary, any of which could be used inplace of another. Consistent with one aspect of the invention, apparatusis provided for precise automated stamp placement upon a targetsubstrate. Consistent with another aspect of the invention is anapparatus for the automated removal of stamps or labels from a backingmaterial. The backing and stamps can be, for example, in an individualsheet, or the sheets can be folded into a booklet configuration.

Consistent with another aspect of the invention, a computer-readablemedium storing program instructions is provided which, when executed,enables the user to select a desired stamp or multiple stamps from agiven sheet for placement on a target substrate. The user can select thetarget substrate, the dimensions thereof, and the desired placementlocation and configuration for the desired stamps. Alternatively, theexecuted program will select the location and configuration of stampplacement based on at least one of the selected stamps and the selectedtarget substrate. The user can select a sheet of stamps from acollection of the same and further select the desired stamps containedtherein. Alternatively to selecting a target substrate from a group, theuser can define the dimensions of the target substrate. Also, the usercan select printing of a postmark onto a stamp-affixed-target substrate.

Consistent with another aspect of the invention, a method is providedfor removing pressure adhesive indicia from their backing sheet andaffixing the removed labels to a target substrate. Consistent withanother aspect of the invention there is provided a method for returningremoved adhesive indicia, e.g. stamps, which are not affixed to asubstrate, to a second backing for future use and or accountingpurposes. A second backing is of course, not essential, and placement ofadhesive indicia upon any paper which is fed out to an accounting andsalvage station is commensurate with aspects of the invention.

Consistent with another aspect of the invention there is provided asystem for removing pressure adhesive stamps from their backing sheetand affixing the same to a target substrate. The automated systemaffixes stamps to the target substrate with both speed and precision ofplacement. Desired stamps can be removed from a backing, can be placedon variable locations upon the target substrate, and can be affixed inthe desired orientation with precise spacing between stamps. Theprecision of affixation afforded by this system is commensurate withphilatelic standards and is suitable for all pressure adhesive labelswhere rapid and precise placement is desired for cosmetic or otherreasons.

The system enables loading of target substrates at large into a hopper,feeder, or large collecting container. Target substrates areautomatically, guided and moved throughout the system being positionedwith accuracy in an affixing station and being subsequently transportedto an outfeed area upon processing completion, where processing mayinclude printing of a postmark upon affixed stamps. A magazine, hopper,or other storage apparatus is loaded with sheets of stamps forsubsequent feeding to the removal apparatus.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several embodiments of theinvention and together with the description, serve to explain theprinciples of the invention.

FIG. 1 is perspective view of a system for removing pressure adhesivelabels from a backing and affixing labels to a target substrate,consistent with the present invention.

FIG. 2 is block diagram of a system consistent with the presentinvention.

FIG. 3A and FIG. 3B shows a substrate feeder consistent with the presentinvention.

FIG. 4A, FIG. 4B, and FIG. 4C shows a pair of sheet units consistentwith the present invention.

FIG. 5A, FIG. 5B, and FIG. 5C illustrate the various components of apickup unit consistent with the present invention.

FIG. 6 shows a suction plate, consistent with the present invention.

FIG. 7A, FIG. 7B, and FIG. 7C shows a suction unit consistent with thepresent invention.

FIG. 8A, and FIG. 8B illustrates components in a peeling area,consistent with the present invention.

FIG. 9A, and FIG. 9B shows an affixing unit consistent with the presentinvention.

FIG. 10A, and FIG. 10B shows one of a pair of salvage units consistentwith the present invention.

FIG. 11 shows a cancellation unit consistent with the present invention.

FIG. 12 shows an output unit consistent with the present invention.

FIG. 13A, and FIG. 13B shows an inspection system consistent with thepresent invention.

FIG. 14 shows a flow diagram of the operator interface protocol for thesystem of removing pressure adhesive stamps and affixing the stamps to atarget substrate.

FIG. 15A, FIG. 15B, FIG. 15C, and FIG. 15D illustrates a method ofpressure adhesive stamp removal, consistent with an exemplary embodimentof the present invention.

DETAILED DESCRIPTION

FIG. 1 is perspective view of an automated system 10 for removingpressure adhesive labels from a backing and affixing labels to a targetsubstrate, consistent with the present invention. FIG. 1 shows the majorareas and units of system 10 and their physical positions relative toeach other in one embodiment.

Consistent with the invention, FIG. 2 is block diagram of an automatedsystem 10 for removing labels, such as stamps, from a backing andaffixing them to a target substrate, such as an envelope. System 10 mayinclude a target substrate feeder unit 100, which may be a hopper orlarge collector apparatus. System 10 may also include a pair of sheetunits, or stamp sheet units, 200 and an affixing station 300. System 10may further include a pair of salvage units 400, a cancellation unit500, an output unit 600, and an inspection unit 700. A control unit maybe provided and coupled to substrate feeder unit 100, sheet units 200,stamp affixing unit 300, salvage units 400, cancellation unit 500,output unit 600, and inspection unit 700 by connections, not shown.

In general operation of one embodiment consistent with the invention, asheet unit 200 picks up a sheet of stamps and removes the backing fromthe sheet, while holding the individual stamps. The stamps are thentransported to affixing station 300, where the stamps, eitherindividually or in groups, are affixed to envelopes supplied fromsubstrate feeder unit 100 by a transport system. The envelopes withaffixed stamps may then be transported to cancellation unit 500 where animprint, such as a cancellation, is place on the envelopes. Afterpassing through inspection unit 700, the envelopes, with affixed stamps,are transported to output unit 600, which processes the envelopes into aform suitable for packaging. One sheet unit 200 may operate as describedabove, while the other sheet unit 200 is off-line, being configured tohandle a different size sheet, as will be described below in greaterdetail. In alternate embodiments, system 10 may include only a singlesheet unit 200 and salvage unit 400.

FIGS. 3-13 provide a more detailed view of respective major componentsshown in FIGS. 1 and 2. FIG. 3 is an illustration of a substrate feeder100 which includes a 6 substrate hopper 110 and a first transportmechanism 120. In one embodiment, the first transport mechanism maybe anindexing belt. In other embodiments, the substrate feeder comprises alarge collector apparatus, and in yet another substrate hopper 110 is afriction feeder. In various embodiments, the target substrate maybe anenvelope, a card, or a package. Still further, the package could be apackage of consumable goods. The substrate feeder supplies a singlesubstrate to affixing station 300 at an affixing location. Substratesare fed onto transport mechanism 120 singly and then move up thetransport line to the point where affixing occurs.

One or more indexing belts, as shown for example in FIG. 3, move thetarget substrate through system 10 (FIG. 1). These belts may travel justbelow the surface upon which the substrate rides. The separation of thebelts may be adjustable by use of various size magnetic spacer plates(not shown) Pusher members, or “flights,” mounted in the belt push thesubstrate along. In affixation station 300, a front pin, not shown,restricts forward movement of the substrate when positioning the samefor affixing the stamps. The indexing belts maybe driven by timingpulleys, with the drive pulleys at the output unit 600 end of themachine and idler pulleys at the substrate feeder unit 100 end. Bothdrive and idler pulleys maybe attached to timing hubs which are mountedon keyed shafts. The pulleys maybe adjustable along their respectiveshafts to accommodate different widths of target substrates anddifferent belt separations. Generally, it is sufficient to move the beltclosest to the feeder only.

Guide rails (not shown) run along the whole length of the system andmaybe magnetically attached to the top plates. The position of the railsshould be adjusted to accommodate different target substrate sizes. Therails maybe made in short lengths, such that excessive magnetic forcedoes not oppose desired movement or repositioning. The rails maybemounted end to end, forming a smooth connection from one rail piece tothe next.

Sheet units 200 may comprise a drawer frame 202 and a lifter 204, asshown in FIGS. 4a and b, respectively. FIG. 4a is a top view of a threedimensional frame while FIG. 4b is a side cross-section view. The hopperdrawers 20 and 25 (FIG. 1) may slide into the front and back drawerframes 202 (FIG. 4a ). Sheets of stamps maybe inserted into a drawer 20or 25 by an operator as a stack on a lift plate 206 (FIG. 4a ). FIG. 4cshows lifter 204 from a front cross sectional view.

Drawer 20 or 25 (FIG. 1) has a secondary container (not shown) inside,which is mounted on slides that allow it to be moved backwards andforward within the drawer. Within the secondary container are a numberof vertical retainers (not shown) which allows various size lift plates206 (FIG. 4a ) to be fitted, to accommodate various sizes of sheets.

Lifter 204 operates from beneath the lift plate 206 and raises liftplate 206 supporting the stack of sheets to a position where a pickupunit (described below) can remove a single sheet from the stack. Drawer20, 25, is locked in the closed position by a pneumatic plunger andmaybe released and allowed to open via a push button (not shown). Thispush button maybe on a safety circuit to prevent release of the drawerduring certain periods of the system operation cycle.

FIG. 5a shows a cross section of a pickup unit 250 consistent with thepresent invention. Although the embodiment of system 10 shown in FIGS. 1and 2 operates with a pair of pickup units at either side of feeder unit200, FIG. 5a shows a single pickup unit 250. The purpose of pickup unit250 is to pick up and transfer a sheet of stamps from lift plate 206 toa peel unit (peel areas 60, 65, FIG. 2), to the affixing station 300(FIG. 1), and then return to the salvage unit 400 (FIG. 1) where itdeposits any unused stamps and the sheet margins.

Referring to FIG. 5a , pickup unit 250 may include a suction plate 252and a plurality of suction units 256 mounted thereon. Turning to FIG. 5b, a top view of the suction plate 252 shows suction units 256 mountedthereon as well as a plurality of miniature electrically-operated vacuumvalves 254 and a plurality of connection hoses 258 which connect valves254 to suction units 256. Pickup unit 250 may also include a pickupplate 258, and a transport system 260 (shown in FIG. 5a ). Valves 254(FIG. 5b ) may be arranged in three banks, each parallel to one side ofsuction plate 252, where FIG. 5b shows two valve banks with hoses 258extending towards these two banks and towards a third side of thesuction plate 252. Suction units 256 may be arranged in an array of, forexample, sixty suction units formed as five columns of twelve units.Connection hoses may be remove-ably attached to respective valves 254and suction units 256 to provide different configurations, as desiredfor various operational runs of system 10 to process various types ofsheets.

Turning to FIG. 5c , each bank of valves 254 may be connected to avacuum manifold 255, which may in turn include a component for removableattachment to a vacuum source. Similarly, each valve 254 may beelectrically connected to a connection fitting and removably connectedto terminals of control system 800 (FIG. 2). The entire suction plate252, with included valves 254 and suction units 256 may thus be quicklyand conveniently removed from pickup unit 250 and replaced with anothersuction plate 252 having a different configuration of valves 254 andsuction units 256.

As may be seen more clearly in FIG. 7, suction units 256 may be formedof a suction block 260 including a vacuum port for receiving aconnection hose 258, one or more suction tubes 262, and a suction cup264, formed as a unit. A pneumatic passage is formed from the vacuumport of suction block 260, through suction tubes 262, to suction cup264. Suction cups 264 are preferably bellows-type suction cups

Each suction unit 256 may also include a contact nub 266 and a spring268, to provide a spring-loaded mounting of suction unit 256 to suctionplate 252. That is, suction tubes 262 movably extend through suctionplate 252, with suction cup 264 and suction block 260 on opposite sidesof suction plate 252. Spring 268 maintains suction cup 264 in proximityto suction plate 252. However, downward pressure against nub 266 willcause suction cup 266 to move to a second position spaced away fromsuction plate 252. Contact nub 266 may be a nylon domed nut.

Referring now to FIG. 6, pickup unit 250 includes an X-Y transportmechanism 280, which enables the suction plate 252 to move withprecision in a horizontal plane from a position over the stack of sheetson lifter 204 (FIG. 4a ) and to a position in affixing station 300 overthe target substrate. Stamps separated from their backing are moved intoposition via the X-Y transport system of the pickup unit, shown in FIG.6, to the affixing station 300 (FIG. 1).

Under control of control unit 800, transport mechanism 280 positionspickup unit 250 over the stack of sheets in lifter 204. A pickup plate258, above and parallel to suction plate 252 is then lowered by controlunit 800 into contact with nubs 266 of suction units 256. Pickup plate258 continues to descend, compressing springs 268 of suction units 256until suction cups 264 come into contact with the top sheet on lifter204. Control unit 800 then actuates vacuum valves 254 to deliver suctionto suction units 256, causing the top sheet to be held by vacuum againstsuction cups 264. Control unit 800 then raises pickup plate 258,allowing springs 268 to raise suction cups 264 into proximity withsuction plate 252, raising the sheet of stamps.

After being removed from the lifter and before being transported to theaffixing station, the sheet of stamps is “peeled,” separating the stampsfrom the sheet backing. Turning to FIG. 8, the peeling area may includegrippers 284, 285, a pickup plate 258, and peel plate 270. To initiateseparating a backing sheet from stamps, a pickup unit 250 is controlledby control unit 800 (FIG. 2) to move a sheet of stamps to the peelingarea 60, 65 (FIG. 1) onto a peel plate 270 (FIG. 8). While the suctioncups 264 maintain control of the stamps, one or more grippers, forexample, grippers 284, 285 of pickup unit 250 clamp onto the selvage, orborder area, of the sheet where no stamps are present. Grippers 284, 285clamp onto opposite sides of the sheet. Briefly, gripper 284 pulls thebacking sheet in a downward direction along an edge of peel plate 270,removing the backing from the stamps, which are still held by vacuum tothe suction cups. Exemplary peeling operations will be described ingreater detail below.

The suction plate X-Y mechanism 280 (FIG. 6), moves the stamps underaccurate control of control unit 800 in the X-Y direction in ahorizontal plane, to a precise location directly over a substrate on thebelt of transport mechanism 120. Transport mechanism 120 has indexingcapability, that is, it is capable of transporting and stopping thesubstrate, also in a precise location.

Turning to FIG. 9, an affixing member 410 is mounted on a second X-Ytransport mechanism 420, which moves affixing member 410 to a preciselocation above pickup unit 250, as determined by operator-enteredcommands supplied to control unit 800. Affixing member 410 may be, forexample, a pneumatically-operated plunger.

Control unit 800 actuates affixing member 410, causing it to descendsinto contact with a nub 266 of precisely selected suction unit 256.Spring 268 of the selected suction unit 256 compresses and therespective suction cup 264 then descends, causing the respective stampheld by suction cup 264 to move into contact with a substrate 290,resting on bed plate 295. While the stamp is in contact with substrate290, control unit 800 actuates the valve 254 corresponding to theselected suction unit 256, removing vacuum from the suction cup andreleasing the stamp. The pressure adhesive of the stamp causes the stampto be affixed to substrate 290. Control unit 800 then actuates affixingmember 410, causing it to lift, allowing spring 268 to return suctioncups 264 into position in proximity to suction plate 252.

Although the above operation was described with one suction cup persuction unit, in certain applications it may be desirable to provide aplurality of, for example, four, suction cups per suction unitSimilarly, in certain applications it may be desirable to provideaffixing unit with a broad strike surface, such that it contacts morethan one suction unit.

The stamp affixing operation is programmable through an operatorinterface to hold substrate 290 in position as pickup unit 250 andaffixing member are translated to precise desired locations tosequentially affix additional stamps on other locations of substrate290. This operation is particularly useful for instances when it isdesired to affix multiple stamps from a given design or series ofstamps. Alternately, programming commands may instruct the transportmechanism 120 to advance following each affixing step, preciselypositioning the next substrate beneath the positioning member so that asingle stamp may be affixed to each target material, each in the sameposition on the subsequent substrates. When the affixing procedure iscompleted on a substrate, it is transported away from affixing station300 toward output unit 700, where it may be dropped onto a conveyor beltrunning perpendicular to transport mechanism 120. From this point, anoperator may collect the finished product.

FIG. 10 shows salvage unit 400, which is used to collect unused stampsand sheet margins for operator disposal. After depositing the requirednumber of stamps from the sheet onto target substrates at affixingstation 300, pickup unit 250 moves back toward sheet unit 200 to thesalvage unit 400. There, control unit 800 causes a pressure plate,activated by four (4) pneumatic cylinders, to descend onto suction plate252 depressing all spring-loaded vacuum cups 264 onto a continuous rollof salvage paper that passes over a stamp deposit plate of salvage unit400.

In another embodiment, stamps unaffixed to target substrates are affixedat salvage unit 400 to a second backing material. Stamps on this secondbacking material may be collected for accounting. In still anotherembodiment, sheets, rather than rolls can be used to mount unused stampsupon.

In some embodiments, all stamps from a sheet may not be desired to beaffixed onto a target substrate. This would often occur when affixingspecific designs from a multiple design sheet or a specificconfiguration, such as a plate number block of four stamps. In such anembodiment, prior to pickup unit 250 returning to sheet unit 200 to pickup another sheet of stamps, it first drops the entire array of suctioncups 264 onto a platform 504 to release any unused stamps. The platform504 is covered with backing paper 564 for later reuse, or other paper,on a roller mechanism 574, 576. Any remaining stamps are affixed to thispaper on platform 504 which is automatically advanced by a take uproller. At the end of a run or affixing period, the roll of paper 564may be retrieved and any reaffixed stamps counted. Since stamps haveinherent monetary value, this controlled method of disposing of unusedstamps allow appropriate accounting and inventory in the instance ofnon-backing paper and reuse in the case of backing paper.

FIG. 11 shows cancellation units 600 which, in one embodiment, maycomprise one or more Tampon printers 602. A printing pad comprises anengraved image of, for example, a postmark. Alternatively, multiple padsmay be combined to form an intricate postmark when printed incombination. In other embodiments a one or more digital printers 603 incancellation unit 400, may print a postmark on the target substrate andthe affixed stamps. A series of postmarks may be imprinted oralternatively a series of printing stages may form a complex postmark.The digital printers can form black and white or multi-coloredpostmarks. Personalized postmarks are possible in accordance withanother embodiment of the present invention.

FIG. 12 shows an output unit 600 consistent with the present invention.An outfeed unit can, in one embodiment, be programmed in control unit800 to stack the affixed substrates. Both the number of substrates in astack and an offset spacing between individual substrates within a stackcan be specified, for example, 25 and 0.5 in, respectively. Dischargerollers of output unit 700 may be positioned at the end of system 10 andeject the finished product unto a discharge conveyor. The dischargerollers may run at a faster speed than transport mechanism 120, whichallows the product to be drawn away from the pushers on the indexingbelt of transport mechanism 120.

FIG. 13 shows an inspection unit 700, which may optionally be used withsystem 10, consistent with the present invention. FIG. 1 shows thephysical location of inspection unit 700 in relation to other systemcomponents. Inspection unit 700 automatically inspects affixed (and, ifapplicable, postmarked) substrates for compliance with quality orinspection standards. These standards are maybe programmed into controlunit 800 and the user can select the parameters to evaluate and thetolerances for each parameter. Parameters which can be inspectedinclude: presence of a stamp, position of any or all stamps within 0.02in of the desired placement with respect to the substrate and adjacentstamps, and the presence and positioning of a postmark. Alternatively,the inspection parameters may look at the presence and position of ablock or group of stamps with or without a postmark as a whole. Adigital camera 702 (FIG. 13) mounted within the inspection stationaccommodates accurate evaluation of various sized target substrates andvarious stamp configurations. The sensitivity of the inspection isadjustable. For example, the programming user can adjust sensitivity byselection or input of acceptable tolerances. The depth of field or fieldof view of the camera can be varied by, among other means, changing thecamera position relative to the substrate viaadjustable-camera-mounting, or adjusting the camera aperture. Theinspection station can even be programmed to reject the stamp itself,for example, if it is defective or torn. Access to inspection programparameters may be provided to the user in inspection unit 700 via atouch screen 705 (FIG. 13). Inspection unit 700 may include a counter totrack the results, such as the number of rejections identified, from theinspection process.

Control unit 800 may be a standard programmable industrial or personalcomputer. Control unit 800 may include a processor, a memory unit and amass storage unit. As shown in FIG. 2, an operator interface screen 900coupled to control unit 800 may provide the user with numerous optionsto program control unit 800. The programmable instructions, which whenexecuted by the processor, may perform a method which includes removingpressure adhesive stamps, and affixing the stamps to a target substrate,selecting a target substrate 410, as shown for example in FIG. 14. Thetarget substrate can be selected from a few or a multitude of substrateoptions to include a sheet of paper, an envelope, a card, or a package415. The operator can enter numerically 422 or choose by displayedoptions the dimensions of the target substrate in a stamp affixationplane 420.

The operator can also select a sheet of stamps from a collection ofsheets or may specify the number of stamps, their size, andconfiguration 432 on the sheet 430. Next, the operator can select any ofor all of the stamps for affixing to the target substrate 435.

The operator can indicate the desired placement location of eachselected stamp 440. In another embodiment, the placement location isdetermined by characteristics of the target substrate and the selectedstamp or group of stamps 445.

Other programmable options include, selecting a desired postmarkapplication 450 and inputting the height of the target substrate, normalto the affixation plane 455.

In yet another embodiment, an outfeed unit 600 (FIG. 12) and a rejectionunit 95 (FIG. 1) facilitate moving affixed substrates out of anautomated system. These units are housed downstream of the inspectionunit 90, as shown in FIG. 1. The outfeed unit may comprise rollers and aconveyor and can, in one embodiment, be programmed to stack the affixedsubstrates. Both the number of substrates in a stack and an offsetspacing between individual substrates within a stack can be specified,for example, 25 and 0.5 in, respectively.

The rejection unit 95, ejects substrates, which fail to meet inspectionstandards, out of the system into a collection apparatus before thesubstrate would enter the outfeed unit.

In another embodiment, system 10, as shown in FIG. 1, counts the numberof target substrates loaded into the feeder, the number of acceptableaffixed substrates that have been outfed and the number of substrateswhich have been rejected and ejected from system 10.

In another embodiment of system 10, the substrate is tracked as itproceeds through the system, for example in the feeder 15, the affixingunit 81, in a first cancellation unit 80, or in the inspection station90 (FIG. 1).

MOVE to END After affixing the desired stamps, the target substrate istransported through a postmark station in the cancellation units 80,where cancellation occurs if desired and programmed. Following thecancellation unit, substrates enter the inspection and rejection units,290 and 295, respectively.

Embodiments of the stamp affixing system, apparatus, and methodconsistent with the invention may perform the task of backing removaland stamp affixing on the target material at a rate of 2400 stamps perhour, a significant improvement over the manual rate.

Peeling Operation

FIG. 8 shows grippers 284, 285 and peel plate 270 according to anembodiment of the apparatus operating in peel areas 60 and 65 (FIG. 1).In this embodiment, suction units 264 not only translate horizontallywith respect to peel plate 270 on which the sheet rests, but alsoslightly in a vertical direction, as shown in FIG. 8. This verticalmovement is produced by a ramp portion 259 of pickup plate 258.

As suction plate 252 is translated horizontally to the right withrespect to the stationary pickup plate 258, by transport mechanism 280,nubs 266 follow the upwardly curving surface of ramp portion 259, at theedge 271 of peel plate 270. The effect is to separate the column ofstamps held by suction units 264 in contact with ramp portion 259 fromthe remainder of columns of stamps on the sheet. In another embodiment,a pivot mechanism 287 causes gripper 285 to move vertically downwardwith respect to peel plate 270 before translation of the stamps or thebacking, causing a crease in the backing.

Turning to FIGS. 15A-D, an embodiment of the peeling process is shown instill greater detail. The stamps of the sheet are removed from backing289 while the suction cups 264 hold the stamps. Backing 289 is grippedby grippers 284 and 285 on opposite sides of the sheet, on the border orselvage of the sheet. A slight force is applied to gripper 284 to pullit away from gripper 285 to put the sheet in tension. (Note thatmovement of the sheet is to the left in FIGS. 15A, 15B, 15C, and 15D,the opposite direction from FIG. 8) Gripper 284, suction units 264, andgripper 285 move at the same speed such that the stamps (held by suctioncups 264) and backing 289 of the sheet move in parallel across peelplate 270. As shown in FIG. 8, grippers 284 and 285 are driven byseparate server motors. Perforations in the stamps of the sheet, whenpresent, run parallel to the direction of translation of the stamps.FIG. 15C shows the backing 289 completed separated from the stamps 32and each stamp secured to a suction cup 264.

FIG. 15D shows the backing separated from the stamps and collected inbacking dump sites, e.g. 70 and 75 in FIG. 1. The stamps and backing areseparated at the edge 47 of the peel plate 270 (FIGS. 8 and 15C).

A sensor detects the position of the affixing head before release ofsuction on the suction head or heads.

In still another embodiment, the front gripper 284 which is mounted on avertical slide, is pivoted 30.degree. over a “knife” edge 47 of peelplate 270 (FIG. 8), by a small pneumatic cylinder; this has the effectof separating the backing sheet from the stamps, which are still held onthe vacuum cups of the pickup unit. Alternatively, the front gripper 284is moved vertically down slightly, e.g. by 1 mm, putting tension on thestamp sheet and assisting in removing the backing sheet from the stamps.

The front gripper, rear gripper, and pickup unit now move together toremove the complete backing sheet from the stamps. On reaching aposition where the last stamps have been removed, the rear gripper jawsare opened and the front gripper jaws carry the backing sheet down tothe ‘backing sheet dump’ drawer, were it is released.

While FIGS. 15A-D show a one-by-three array of suction units, alternateembodiments include, but are not limited to, five by 12 arrays.Individual suction cups 264 can hold an individual stamp or more thanone suction cup 264 can hold a single larger stamp.

Other embodiments consistent the invention will be apparent to thoseskilled in the art from consideration of the specification and practiceof the invention disclosed herein. It is intended that the specificationand examples be considered as exemplary only, with a true scope andspirit of the invention being indicated by the following claims.

1-20. (canceled)
 21. A method for affixing a stamp to a targetsubstrate, the method comprising: engaging a sheet of stamps by way of apickup device, the sheet comprising a plurality of stamps, an adhesiveside, and a backing member covering the adhesive side; transferring theengaged sheet to a peeler by way of the pickup device; removing at leasta portion of the backing member from the engaged sheet by way of thepeeler, thereby exposing at least a portion of the adhesive sidecorresponding to at least one of the plurality of stamps; bringing, byway of the pickup device, the exposed portion of the adhesive sidecorresponding to the stamp into contact with a target substrate, therebyaffixing the stamp to the target substrate; and disengaging the pickupdevice from the stamp.
 22. The method of claim 21, wherein the pickupdevice comprises at least one suction cup and engaging the sheet ofstamps comprises creating suction between the suction cup and the sheet.23. The method of claim 22, wherein disengaging the pickup device fromthe at least one stamp of the engaged sheet of stamps comprises ceasingto create suction between the suction cup and the sheet.
 24. The methodof claim 23, wherein ceasing to creation suction between the suction cupand the sheet comprises deactuating a vacuum valve coupled to thesuction cup.
 25. The method of claim 21, wherein the pickup devicecomprises a plurality of vacuum valves and engaging the sheet of stampscomprises creating a vacuum between a portion of the pickup device andthe sheet.
 26. The method of claim 25, wherein disengaging the pickupdevice from the at least one stamp of the engaged sheet of stampscomprises ceasing to create the vacuum between the portion of the pickupdevice and the sheet.
 27. The method of claim 21, wherein bringing theexposed portion of the adhesive side corresponding to the stamp intocontact with the target substrate comprises displacing a portion of thepickup device with an affixing member.
 28. The method of claim 27,wherein displacing the portion of the pickup device with the affixingmember comprises moving the affixing member using a programmablecontroller.
 29. The method of claim 27, wherein the affixing member is apneumatic plunger.
 30. The method of claim 21, wherein the adhesive sideof the engaged sheet comprises a pressure adhesive.
 31. The method ofclaim 21, wherein the peeler comprises a gripper and removing theportion of the backing member of the engaged sheet of stamps comprisesgripping the portion of the backing member and pulling the portion ofthe backing member away from the engaged sheet of stamps.
 32. The methodof claim 31, wherein the peeler further comprises a removal plate andpulling the portion of the backing member away from the engaged sheet ofstamps comprises pulling the portion of the backing member against theremoval plate.
 33. The method of claim 31, wherein the peeler comprisesa pivot mechanism configured to pivot the gripper and pulling theportion of the backing member away from the engaged sheet of stampscomprises creasing the engaged sheet of stamps by pivoting the gripper.34. The method of claim 31, wherein the plurality of stamps are arrangedin columns on the engaged sheet and the peeler comprises a ramp memberconfigured to initiate a separation of adjacent columns of the stampswhile the gripper pulls the portion of the backing member away from theengaged sheet of stamps.
 35. The method of claim 21, further comprisingcollecting, by way of a salvager, one or more portions of the engagedsheet of stamps remaining on the pickup device after the at least onestamp has been affixed to the target substrate.
 36. A method foraffixing a stamp to a target substrate, the method comprising: engaging,by way of a pickup device, a sheet of a plurality of sheets of stamps,the sheet comprising a plurality of stamps, an adhesive side, and abacking member covering the adhesive side; transferring the engagedsheet of stamps to a peeler by way of the pickup device; removing atleast a portion of the backing member from the engaged sheet of stampsby way of the peeler, thereby exposing at least a portion of theadhesive side corresponding to at least one of the plurality of stampsof the engaged sheet; positioning the pickup device and the sheet ofstamps engaged therewith over an affixing station; bringing, by way ofthe pickup device, the exposed portion of the adhesive sidecorresponding to the stamp into contact with a target substrate locatedon the affixing station, thereby affixing the stamp to the targetsubstrate; and disengaging the pickup device from the stamp.
 37. Themethod of claim 36, wherein the pickup device comprises at least onesuction cup and engaging the sheet of stamps comprises creating suctionbetween the suction cup and the sheet.
 38. The method of claim 37,wherein disengaging the pickup device from the at least one stamp of theengaged sheet of stamps comprises ceasing to create suction between thesuction cup and the sheet.
 39. The method of claim 36, wherein bringingthe exposed portion of the adhesive side corresponding to the stamp intocontact with the target substrate comprises displacing a portion of thepickup device with an affixing member.
 40. A method for affixing a stampto a target substrate, the method comprising: supplying, by way of asheet device, a plurality of sheets each comprising a plurality ofstamps, an adhesive side, and a backing member covering the adhesiveside; supplying, from a feeder to a surface of an affixing station, atarget substrate to which one or more of the stamps are to be affixed;engaging, by way of a pickup device, a sheet of the plurality of sheetsof stamps supplied by the sheet device; transferring, by way of thepickup device, the engaged sheet of stamps from the sheet device to apeeler; removing at least a portion of the backing member from theengaged sheet of stamps by way of the peeler, thereby exposing at leasta portion of the adhesive side corresponding to at least one of theplurality of stamps of the engaged sheet; positioning the pickup deviceand the sheet of stamps engaged therewith over the affixing station;bringing, by way of the pickup device, the portion of the exposedadhesive side corresponding to the stamp into contact with the targetsubstrate located on the affixing station, thereby affixing the stamp tothe target substrate; and disengaging the pickup device from the stamp.